Transformer Winding Frame Layout for Compact Core Nesting
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Solution Overview
Problem
The existing transformer design has a protruding winding part that occupies additional space, resulting in a larger overall size, which hinders miniaturization efforts.
Innovation Solution
The transformer design incorporates a winding frame with a mounting part that houses a first magnetic core, allowing the winding to be wound on the outer side of the magnetic core, thereby optimizing the use of space inside the winding frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the winding part is disposed protruding from the base, then the winding can be properly installed and connected, but the space below the winding part cannot be used, resulting in a larger overall size
Solution Approach 1:
The patent changes the spatial arrangement by allowing the magnetic core to extend vertically beyond the winding in the height direction, transforming the traditional horizontal layering into a three-dimensional overlapping configuration. This dimensional change enables the magnetic core to utilize the vertical space that would otherwise be wasted, thereby reducing the overall footprint of the transformer while maintaining proper winding installation.
Solution Approach 2:
The patent implements a nested arrangement where the winding is wound around the magnetic core, and the magnetic core extends beyond the winding boundaries. The insulating structure then encapsulates both the winding and the protruding magnetic core portions, creating a nested configuration that maximizes space utilization and reduces the overall transformer volume.
2Volume of moving object
If the magnetic core and winding occupy the same vertical space, then the transformer length in the vertical direction is reduced, but the structural complexity increases
Solution Approach 1:
The patent merges the functions of multiple components into an integrated insulating structure that simultaneously serves as: (1) the insulating barrier between the winding and external environment, (2) the structural support for the protruding magnetic core, and (3) the encapsulation for the winding. This consolidation reduces the number of separate parts and simplifies the overall structure despite the complex three-dimensional arrangement.
Solution Approach 2:
The insulating structure is designed with multi-functionality, serving as both the insulating barrier and the structural framework that supports the magnetic core's protrusion. This universal component performs multiple functions that would traditionally require separate elements, thereby reducing structural complexity while enabling the compact vertical arrangement.
Data Source
AI summary
A transformer includes a winding frame, a first magnetic core, a second magnetic core, and a winding. The winding frame includes two side walls along a first direction and a bottom wall. Along a second direction, both sides of the bottom wall are each provided with a stop plate. A length of the stop plate in a third direction is less than a length of each of the two side walls in the third direction. The bottom wall, the two side walls and the two stop plates together around form a mounting part. The first magnetic core is at least partially located in the mounting part. The winding is wound on an outer side of the first magnetic core, the bottom wall and the two stop plates. The second magnetic core, outside of the winding, is provided covering part of the winding, and is connected to the first magnetic core.